Process for making a baked cup shaped food product

ABSTRACT

A process for manufacturing a food product, a food product produced thereby and a plant for production of the food product. The food product may have a generally truncated cone shape which allows the product to be stood on its base. The baking mixture is inserted into mould cavities of a tray and fitting a second tray with male formers corresponding to the mould cavities into the first tray prior to baking. The trays may pass through the oven on an endless conveyor as part of a plant which includes a filling station, for filling the baked product with sweet or savoury fillings, and a freezing station. The food product is baked with a high liquid content to allow for the formation of a thin, tough impervious layer of gelatinised starch skin to form on the product surfaces.

This is a nationalization of PCT/NZ00/00149 filed Aug. 4, 2000 andpublished in English.

FIELD OF THE INVENTION

The invention relates to a process for manufacturing a food product, afood product produced thereby and a plant for production of the foodproduct. Particularly the invention relates to a food product, such as agenerally truncated cone shaped product, pie base or the like whichallows the product to be stood on its base.

BACKGROUND OF THE INVENTION

At present a large number of processes are described in patent and otherliterature for producing food products and because of the number thereare too many to separately detail.

One such process is that described in U.S. Pat. No. 5,626,897. Thisprocess describes using a flat strip of dough which is wound to form acone shaped product. A difficulty with this product is that it is notfree standing and that a special coating is required to help seal theoverlapping sections of the spirally wound dough to form a cavity inwhich a filling is placed.

SUMMARY OF THE INVENTION

An object of the invention is to provide a process and plant formanufacturing a food product which at least overcomes the disadvantagesidentified above and provides an end product which offers a consumer analternative choice.

Further objects and advantages of the invention will become apparentfrom the following description which is given by way of example.

According to a first aspect of the invention there is provided a processfor producing a food product, the process including the steps of:

-   -   mixing ingredients as herein described to form a consistent mix;    -   placing the mix into cavities of a tray;    -   fitting to the tray a lid incorporating male formers or members        adapted to form with the cavities in the tray mould cavities of        the same size and shape as the end products;    -   placing the filled and capped tray in an oven for a        predetermined time at a preset temperature to thereby par-bake        or fully bake the mix to seal and create an impervious surface        to each end product;    -   removing the tray from the oven;    -   separating the tray and lid;    -   removing the end products from the mould cavities for use as a        food product or for further processing.

The end products are cooled prior to filling.

The end product produced has a low fat content.

The mix can be placed into the cavities of the tray by a depositorsituated above a conveyor on which a series of the trays are moved. Thecavities of the tray(s) are filled successively.

The process can further include steps of pre-cooking appropriate savouryand/or sweet fillings which are inserted automatically into each cavityin the end product.

The filled end product can then be frozen in a blast freezer ready forpackaging and storage in a freezer before transportation for use.

The cavities in the trays and the male members on the lids can be shapedto form a generally truncated cone shaped end product or a pie baseshaped end product as well as other shapes all of which have a basewhich allows them to stand on a surface.

According to a second aspect of the invention there is provided aprocess for producing a food product, the process including the stepsof;

-   -   mixing ingredients as herein described to form a consistent mix;    -   placing the mix into cavities of a tray;    -   placing into each cavity of the tray a pre-prepared filling;    -   fitting to the tray a lid incorporating farmers or members        adapted to close the cavities and force the mix to enclose/cover        the filling;    -   placing the filled and capped tray in an oven for a        predetermined time at a preset temperature to thereby parbake or        fully bake the mix to seal its outer surface to create an        impervious skin to each food product;    -   removing the tray from the oven;    -   separating the tray and lid; and    -   removing the end product from the cavities in the mould for use        in further processing.

The end product being baked with a high liquid content such as watergives an opportunity for a thin, tough impervious layer of gelatinizedstarch skin to form an the product surfaces.

The product being both yeasted and chemically leavened will createpressure against the mould, again early in baking, which helps the buildup of the impervious shell layer.

Flour containing gluten is also necessary as the water is absorbed untilsaturation occurs which when combined with the gluten's formingproperties and heat, provide strength therefore allowing the product toremain stable for easy removal after baking from the moulds. Without thegluten the product would collapse.

According to a third aspect of the invention there is provided a plantfor producing a food product, the plant including:

-   -   a mixing station at which ingredients of a particular food        product are mixed;    -   connecting means from the hopper to a depositor positioned over        an endless conveyer incorporating a plurality of mould trays;    -   a second endless conveyor with mould lids positioned to locate        immediately above the endless conveyor;    -   a baking chamber at an output end of which is a cooling region        and transfer region and through which the endless conveyors        pass;    -   at the cooling and transfer region the baked and products are        removed from the moulds for transfer to either a blast freezer        or to a topping station followed by the option of a topping        station and then to a blast freezer after which the end products        are moved to a packing or storage facility.

The transfer of the mix from the mixing station to the depositor may bevia a pumping mechanism.

The end products may be removed from the moulds by suction at thetransfer station.

The filling station may include an additional topping station.

According to a fourth aspect of the invention there is provided a foodproduct produced from the process or plant as hereinbefore defined whichafter formation or production has liquid holding capacity.

BRIEF DESCRIPTION OF THE DRAWINGS

Particular examples of the invention will now be described withreference to the accompanying drawings in which:

FIG. 1 shows a sectional front view of a tray and corresponding lidshown spaced apart;

FIG. 2 shows a sectional side view of the tray and lid shown in FIG. 1;

FIG. 3 shows a similar view to that in FIG. 1 with the lid situated onthe tray;

FIG. 4 shows a view similar to FIG. 2 with the lid on the tray;

FIG. 5 shows on an enlarged scale a section of the lid at position A onFIG. 1;

FIG. 6 shows in detail on an enlarged scale a section of the trayindicated at position B in FIG. 1;

FIG. 7 shows a detailed view of the tray and lid shown in FIGS. 5 and 6coming or being moved together;

FIG. 8 shows the lid and tray shown in FIGS. 5 to 7 assembled together;

FIG. 9 shows a perspective view of a food product produced by the trayand lid combination shown in FIGS. 1 to 7;

FIG. 10 shows a side view of the food product shown in FIG. 9;

FIG. 11 shows a view from below of the truncated cone shaped foodproduct shown in FIGS. 9 and 10;

FIG. 12 shows a plan view of the food product shown in FIGS. 9 to 11;

FIG. 13 shows a perspective view of a pie base food product;

FIG. 14 shows a side view of the pie base shown in FIG. 13;

FIG. 15 shows a plan view of the pie food product shown in FIGS. 13 and14;

FIG. 16 shows a bottom view of the pie base food product shown in FIGS.13 to 15;

FIG. 17 shows a plan view of a plant for use in production of an endproduct according to the invention;

FIG. 18 shows a side view of the plant shown in FIG. 17;

FIG. 19 shows a plan view of a second example of plant for use in theproduction of an end product according to the invention; and

FIG. 20 shows a side view of the plant shown in FIG. 19.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The ingredients for a mix for producing the generally truncated coneshaped product are selected to suit and the total weight of flour mustbe the same as that of the liquid at about 30° C. and if water isincluded in the recipe then the approximate water temperature should be27°–30° C.

The process steps should follow the directions listed below or the coneswill not release from the trays.

(a) Mixing the Ingredients.

Add instant yeast to bowl just before mixing.

-   1. Mix dry ingredients in bowl for 1 minute on speed 1 or low.-   2. Always use a paddle to mix ingredients.-   3. Water at appropriate temperature. Add oil to water.-   4. Pour combined water and oil to bowl.-   5. Mix for 3 minutes on speed 1 or low.-   6. Stop and check to make sure there is no residue flour at bottom    of bowl. If there is, use a scraper to mix in.-   7. Mix for 1 minute on speed high.-   8. Mix must be used within 60 minutes and no resting time is    required.    (b) Filling Trays-   9. Pour or pump mix into holding tank then to depositor.-   10. Deposit mix into base of tray.-   11. Place lid on base and place in oven.    (c) Bake for Designated Time.    (d) Product Removal-   12. Cones to be cooled completely to ambient temperature.    (e) Optional Filling-   13. Fill cone automatically with appropriate savoury or sweet    fillings.-   14. Transfer to a blast freezer.

The above process steps can be automated.

DEPOSITOR

Control

With control there is no excess mix in moulds and therefore no dried mixdebris in the moulds because of the characteristics of the mix whichseals its outer surface leaving no debris in the moulds. The mix as itrises in the mould forms an uneven upper surface to the product. Thiscan give a scalloped appearance to the upper edge.

MIX

The ingredient list depends on the eventual product required as doesmixing and baking procedures.

Do not change mixing times, speeds or replace paddle.

BAKING PROCEDURE

The combination of ingredients, and mixing method has eliminated theneed for proving.

Mix to be used within an hour. Do not use any which has been resting forlonger as pulling and stretching begins and ultimately the cone may tearwhen baked. A small split can occur which is hardly noticeable and thenwhen the cone is filled, problems will arise due to the extra weightcontained within the cone.

Mix is pumped into holding tanks for depositing into trays.

Mix cannot be stored and remixed or added to other mix. Mixing must beaccurate to alleviate the potential problem of waste. Flour ingredientproportion to water is critical.

Each mould is nearly filled before the lids are placed on their uppersurface. This enables quality control.

The removed cones are ideally placed on an open mesh conveyor to createquick cooling of the cones.

The quicker the cone cools the better the product.

Do not fill cones until totally cool or place empty cones in freezeruntil cool. The cone becomes stable when cool.

Do not leave unprotected filled or empty cones in freezer for more than8 hours maximum or dehydration and contamination of the cone may occur.There is a long term effect which is splitting which can occur. The conecan be packed either stood vertically when frozen or laid side by sideso as to prevent the circular shape becoming oval. They can be stackedinside each other like an ice-cream cone.

Filling

Fill the cone to the level of the lowest scallop edge and do not fillthe cone until it has been cooled.

Appearanc

Smooth shiny cavity wall and smooth even exterior wall.

Taste

Savoury cone is moorish and nutty, and there is no after taste whichindicates high fat, salt or sugar.

Dessert or sweet cone.

Feeling

Firm so it does not fall out of cone when inverted.

Cone and Filling Specifications

The following Table shows the ingredient list for a number of exampleproducts according to the invention.

STANDARD WHOLEMEAL SWEET FRUIT Maximus flour x x x x Harvest — — — —wholemeal Baking powder x x x x Soya flour x x — — Dried yeast x x x xCereform deluxe x x x x royal Milk powder x x x x Vegetable oil x x x xSalt x x x x Sugar — — x x Mixed spice — — — x Soy & linseed — — — —Parmesan cheese — — — — Tomato puree — — — — Fruit — — — x Water +/− x xx xMould Trays

In FIGS. 1 to 8 is shown an example of tray mould 1 and associated lid 2which are designed to create a plurality of truncated cone shaped foodproducts.

The tray mould 1 incorporates a plurality of shaped cavities 3 intowhich male members 4 of the lid 2 fit. The space 5 between the outsideof each male member 4 and its associated cavity 3 forms the mould forthe product.

FIGS. 9 to 16 show the shape of examples of end product which can beproduced.

Plant

In FIGS. 17 and 18 is shown a plant for producing the food products. Theplant in this example is a modified tunnel oven designed to create acontinuous throughput of about 5,000 units per hour.

The plant includes a mixing station generally indicated by arrow 6. Themixing station 6 is linked to a depositor 7. The flow of mixedingredients from the mixing station 6 to the depositor 7 may be by wayof a pump (not shown).

The depositor 7 is situated above an inlet end C of the oven above anendless conveyer 8 on which a plurality of mould trays are mounted. Themould trays move in the direction of the arrow 9 shown. The mould traysconsist of a plurality of cavities the shape of which is similar to theshape of the cavities shown in FIGS. 1 and 2.

The endless conveyer 8 passes through a baking chamber generallyindicated by arrow 10.

Also passing through the baking chamber 10 is a second endless conveyer11 carrying mould lids which at the inlet end C rest on top of the mouldtrays while they pass through the baking chamber 10 to an outlet endgenerally indicated by 12.

At the outlet end 12 of the baking chamber there is situated a coolingchamber and transfer region 13.

In the cooling chamber and transfer region 13 the end products arecooled as quickly as possible.

The end products are removed from the cavities by any suitable meanssuch as a suction mechanism which assists in transfer of the endproducts from the cavities to an output endless conveyer 14 which movesthe end products through the cooling chamber. The rate of movement ofthe conveyer 14 can be adjusted to increase or decrease the dwell timeof the end products. Increasing cooling before the cooled product iseither passed to a filling and/or topping station or direct to a blastfreezer if preferred.

At a filling station 15 the cones may be filled with appropriateingredients and these may be pre-prepared. The ingredients may be toppedat a topping station 16 if a topping is appropriate. The end productsthen pass to a blast freezer 17.

After removal of the end products from the blast freezer 17 they may betransferred automatically by a transverse conveyer system 18 to apacking machine 19 from which cartoned products are transferred forshipment or storage.

In the second example of plant shown in FIGS. 19 and 20 the plantincorporates similar parts to the unit shown in FIGS. 17 and 18 althoughits capacity is increased to 10,000 units per hour.

In this instance the dwell time in the cooling chamber 13 and blastfreezer 17 are increased by increasing the length of the output conveyer14.

In both examples of plant is shown a logo applicator 20. The logoapplicator 20 can be used to apply to the end product a food quality dyein the shape of an appropriate emblem motif or logo to suit particularcustomer's requirements.

The plants as shown can be substantially automated.

Thus by this invention there is provided a process and plant forproducing a food product and a food product produced thereby. The foodproduct may be par baked and filled and is re-heated in an oven beforeuse or if fully baked is re-heated in a microwave.

Particular examples of the invention have been described and it isenvisaged that improvements and modifications can take place withoutdeparting from the scope of the attached claims.

1. A process for producing a food product with an impervious exteriorsurface and low fat content, the process comprising the steps of: mixingdry ingredients for a particular food product in a mixing station with apaddle for one minute, the mixing ingredients including flour; mixingthe flour with a high liquid content for three minutes with a totalweight of the flour being equal to a total weight of the liquid content;depositing the mixed ingredients within one hour of mixing into cavitiesin a plurality of mould trays mounted on a first endless conveyor;positioning mould lids on a second endless conveyor so that the mouldlids locate and close the filled mould trays mounted on the firstendless conveyor; feeding the filled and closed mould cavities through abaking chamber at an output end of which is a cooling region andtransfer region through which the first and second endless conveyorspass; baking the food product with the high liquid content to form athin, tough impervious layer of gelatinized starch skin on surfaces ofthe end product by yeasting and chemically leavening the food product tobuild up the impervious layer; at the cooling and transfer region thebaked end products are removed from the moulds for transfer to either ablast freezer or to a filling station and/or topping station and then toa blast freezer after which the end products are moved to a packing orstorage facility to produce a product with the impervious exteriorlayer.
 2. The process as claimed in claim 1, wherein the transfer of themix from the mixing station to the depositor is via a pumping mechanism.3. The process as claimed in claim 1, wherein the end products areremoved from the moulds by suction at the transfer station.
 4. Theprocess as claimed in claim 1, wherein the filling station includes atopping station.
 5. The process for producing a food product as claimedin claim 1, wherein the mould cavities are in a series of trays and themould lids incorporate male formers or members adapted to form with themould cavities moulds of the same size and shape as the desired endproducts.
 6. The process as claimed in claim 1, wherein the filled andclosed mould cavities are in the baking chamber for a predetermined timeat a preset temperature to thereby par-bake or fully bake the mix toseal and create the impervious surface to each end product.
 7. Theprocess as claimed in claim 6, including the additional step of: placinginto each filled cavity of the mould trays a pre-prepared filling. 8.The process as claimed in claim 6, wherein the end products are cooledprior to filling.
 9. The process as claimed in claim 1, including thefurther step of pre-cooking appropriate savoury and/or sweet fillingswhich are inserted automatically into each cavity in the end productwhich is then frozen in a blast freezer ready for packaging and storagein a freezer before transportation or use.
 10. The process as claimed inclaim 1, wherein the cavities in the trays are shaped to form agenerally truncated cone shaped end product or a pie base shaped endproduct as well as other shapes all of which have a base which allowsthem to stand on a surface.
 11. The process as claimed in claim 1,wherein a temperature of the high liquid content mixed with the flour isin the range of 27–30° C.
 12. The process as claimed in claim 11,wherein a temperature of the high liquid content mixed with the flour isabout 30° C.